Thermoformed structural composites

ABSTRACT

The present invention is generally directed to methods and systems for making thermoformed structural elements and composites, including the use of composites, dissimilar or variable processing materials. End products can have the same outward appearance as those products made by more demanding, more expensive extrusion process or injection process, but the end products can be pre-engineered to have significantly, unexpectedly, improved physical and chemical properties.

RELATED U.S. APPLICATION DATA

This application is a divisional of patent application Ser. No.14/880,764, filed on Oct. 12, 2015, entitled “Thermoformed StructuralComposites”, the entire disclosure of which is incorporated herein byreference. Patent application Ser. No. 14/880,764 is a divisional ofpatent application Ser. No. 13/839,018, filed on Mar. 15, 2013, entitled“Thermoformed Structural Composites”, the entire disclosure of which isincorporated herein by reference.

TECHNICAL FIELD OF THE INVENTION

The present invention is generally directed to methods and systems formaking thermoformed structural elements and composites, including theuse of composites, dissimilar or variable processing materials.

BACKGROUND OF THE INVENTION

There is a major unresolved challenge in recycling mixed plastics andmixed plastics with non-plastic-contaminates. The difficulty with thistype of recycling process is that the different plastics used in therecycling process are not compatible with each other. There is aninherent inability of two or more plastics to undergo mixing orblending, which means that some plastics cannot be mixed together duringthe recycling process. Also, different types of plastics are immiscibleat the molecular level, and there are significant differences inprocessing requirements at the macroscopic level with respect to thedifferent plastic inputs.

Even a small amount of the wrong type of plastic can ruin an entirecontainer or bale of recycled material. Co-mingled material is worthsignificantly less than sorted material. Mixed or co-mingled plasticsare frequently contaminated with such items as metals, paper, pigments,inks, adhesives, carbon fiber, flame retardants, fiber reinforcedplastics, glass filled plastics, cured silicon and rubber.

A primary reason for these differences is the different melting pointsassociated with different plastic resins, or the inability of certainplastics to undergo a “re-melting” process. Plastics involved inrecycling activities can be considered in two broad categories:thermoplastics and thermoset. Comparing these types, in the present art,thermoplastics are much easier to adapt to recycling.

Thermoplastic polymers can be heated and formed, then heated and formedagain and again. The shape of the polymer molecules are generally linearor slightly branched. This means that the molecules can flow underpressure when heated above their melting point. Thermoset polymerplastics, on the other hand, undergo a chemical change when they areheated, creating a three-dimensional network. Thermosets cannot bere-melted or remolded and therefore have been traditionally difficult torecycle. Typical types of thermosetting plastics are Polyurethane (PU),epoxies, polyesters, silicones and phenolics, with vulcanized rubberbeing an excellent example of a thermosetting and alsopolyoxybenzylmethylenglycolanhydride (bakelite).

Materials made from two polymers mixed together are called blends. Ingeneral, polymers cannot be homogeneously mixed with one another, andeven attempting to mix most polymers will result in phase-separatedmixtures.

An example of phase-separated mixtures or immiscible blends ispolystyrene and polybutadiene, which are immiscible polymers. When youmix polystyrene with a small amount of polybutadiene, the two polymerswill not blend together. Polystyrene is generally a stiff, brittle,material that will break or shatter if bent. Polybutadiene separatesfrom the polystyrene into usually small, isolated, sphere-shaped item,and the polybutadiene spheres in the blend are elastic in nature andabsorb energy under stress.

The polystyrene and polybutadiene immiscible blend bends and does notbreak like polystyrene by itself. The immiscible blends of polystyreneand polybutadiene are known as high-impact polystyrene, or HIPS.

Another example of an immiscible blend is one made from PolyethyleneTerephthalate (PET) and poly(vinyl alcohol) (PVA). The blend results inPET and PVA separating into individual sheetlike layers. This blend isparticularly useful in the making of plastic bottles for carbonatedliquids.

“Recycling and Recovery of Plastics,” by Joop Lemmens recognizes arecent trend in the increased use of polymer mixtures, blended polymersand novel plastic combinations. An example of ‘novel’ plastic iscross-linked polyethylene (PEX). Crosslinking polyethylene changes thepolymer from a thermoplastic to a thermoelastic polymer. Once it isfully crosslinked, polyethylene tends not to melt but merely to becomemore flexible at higher temperatures.

Examples of problems in recycling plastics include cases where aquantity of recycled PET is contaminated with a small amount of PVC. ThePVC will release hydrochloric-acid gas before the process temperature tomelt the PET is reached, and the released gas will degrade the PET. Inthe reverse, where a small amount of PET contaminates recycled PVC, thePET will remain in solid form after the PVC reaches its melting point,which results in crystalline PET inhabiting the post-melt-cooled PVCstructure.

A major problem in the recycling of PVC is its high chlorine content ofraw PVC, and the hazardous additives added to the polymer to achieve thedesired material quality. PVC requires separation from other plasticsand sorting before mechanical recycling. PVC recycling is difficultbecause of high separation and collection costs, loss of materialquality after recycling, and the low market price of recycled PVCcompared to virgin PVC.

There are thousands of different varieties of plastic resins or mixturesof resins, and most plastics have a code number or classification.Plastics not identified by code numbers are difficult to recycle. Theseitems, such as computer keyboards, do not fit into the numbering systemthat identifies plastics used in consumer containers.

Bazant & Cedolin address concerns about the stability of structuralcomposites, such as the composites made from recycled materials. Namely,Bazant & Cedolin state: “[t}hree-dimensional instabilities are importantfor solids with a high degree of incremental anisotropy, which can beeither natural, as is the case for many fiber composites and laminates,or stress-induced, as is the case for highly damaged states ofmaterials” and “[t]he typical three-dimensional instabilities are thesurface buckling and internal buckling, as well as bulging and stratafolding.”

Bazant & Cedolin state that “. . . three dimensional buckling modesdescribed . . . no doubt play some role in the final phase ofcompression failures. For example, Bazant (1967) showed that a formulabased on . . . thick-wall buckling . . . agrees with his measurements ofthe effects of the radius-to-wall thickness ratio on the compressivefailure stress of fiber-glass laminate tubes. On the other hand, otherphysical mechanisms, particularly the propagation of fractures or damagebands, are no doubt more important for the theory of compressionfailure. The reason is two-fold: (1) The calculated critical states forthe three-dimensional instabilities require some of the tangentialmoduli to be reduced to the same order of magnitude as some of theapplied stress components, which can occur only in the final stage ofthe failure process; and (2) the body at this stage might no longer beadequately treated as a homogeneous continuum.”

Bazant & Cedolin address “orthotropic composites that have a very highstiffness in one direction and a small shear stiffness may sufferthree-dimensional instabilities such as internal buckling or surfacebuckling. These instabilities, which involve buckling of stiff fibers(glass, carbon, metal) restrained by a relatively soft matrix (polymer),are analogous to the buckling of perfect columns. When the fibers areinitially curved, one may expect behavior analogous to the buckling ofimperfect columns. In particular, the initial curvature of fibers causesfiber buckling, which reduces the stiffness of the composite. It alsogives rise to transverse tensions, which may promote delaminationfailure.”

Urquhart & O'Rourke address three dimensional instabilities as follows:“[w]henever a material is subjected to compression in one direction,there will be an expansion in the direction perpendicular to thecompression axis. When this expansion is resisted, lateral compressivestresses are developed, which tend to neutralize the effect of thelongitudinal compressive stress, and thus increase resistance againstfailure. This is the principle involved in the use of spiral or hoopedreinforcement . . . ”.

Also, Urquhart & O'Rourke state that “[w]ithin the limit of elasticitythe hooped reinforcement is much less effective than longitudinalreinforcement. Such reinforcement, however, raises the ultimate strengthof the column, because the hooping delays ultimate failure . . . ”, andthe material “ . . . continues to compress and to expand laterally, thusincreasing the tension in the bands, while final failure occurs upon theexcessive stretching or breaking of the hooping.” “As long as the bondbetween the . . . ”fiber and the polymer “. . . is effective, the twomaterials will deform equally, and the intensities of the stresses willbe proportional to their moduli of elasticity.”

A structural system's failure mode can be defined as the characteristicsbounded by that known as “catastrophic” or “localized” within the saidsystem, wherein the term “catastrophic” indicates a system-widestructural failure involving progressive individual and sub-systemicstructural element(s) failures and the term “localized” indicates asystem or sub-system arrest of structural failure and/or redistributionof the force(s) which resulted in the initial failure-mode of theinitial failed structural element.

One of the unexpected results of full-scale testing of the presentinvention's physical manifestations, is the damping effect of thepresent invention to structural “shock”, such as the characteristic ofnailing or directly impacting physical samples of the present invention.

U.S. Pat. No. 6,497,956 (956) issued Dec. 24, 2002, to Phillips et al.,teaches that “. . . high density polyethylene (HDPE) . . . ”and “. . .plastic lumber made from HOPE, PVC, PP, or virgin resins has beencharacterized as having insufficient stiffness to allow its use instructural load-bearing applications.” “For example, it is noted thatnon-reinforced plastic lumber products typically have a flexural modulusof only one-tenth to one-fifth that of wood such as Douglas fir, . . . ”U.S. Pat. No. 5,212,223 discusses the inclusion of short glass fiberswithin reprocessed polyolefin and further teaches doing so to increasethe stiffness of the non-reinforced plastic lumber by a factor of 3:4.However, none of the prior art known to applicant is capable offabricating plastic lumber having the structural stiffness and strengthof products made according to the present invention . . . ”

U.S. Pat. App. No. 20070045886, filed Mar. 1,2007, by Johnson teachesthat: “. . . composite lumber is currently used for decking, railingsystems and playground equipment. Sources indicate that there currentlyexists a $300 million per year market for composite lumber in the UnitedStates. It is estimated that 80% of the current market uses a form ofwood plastic composite (WPC). Itis estimated that the other 30% is solidplastic. A wood plastic composite (WPC) refers to any composite thatcontains wood particles mixed with a thermaloset or thermoplastic. . . .The presence of wood fiber increases the internal strength andmechanical properties of the composite as compared to, e.g., woodflour.” And, [f]or or example, the addition of wood fillers into plasticgenerally improves stiffness, reduces the coefficient of thermalexpansion, reduces cost, helps to simulate the feel of real wood,produces a rough texture improving skid resistance, and allows WPC to becut, shaped and fastened in a manner similar to wood.”

Also, “[t]he addition of wood particles to plastic also results in someundesirable characteristics. For example, wood particles may rot and aresusceptible to fungal attack, wood particles can absorb moisture, woodparticles are on the surface of a WPC member can be destroyed by freezeand thaw cycling, wood particles are susceptible to absorbingenvironmental staining, e.g., from tree leaves, wood particles cancreate pockets if improperly distributed in a WPC material, which mayresult in a failure risk that cannot be detected by visual inspection,and wood particles create manufacturing difficulties in maintainingconsistent colors because of the variety of wood species colorabsorption is not consistent. Plastics use UV stabilizers that fade overtime. As a result, the wood particles on the surface tend to undergoenvironmental bleaching. Consequently, repairing a deck is difficult dueto color variation after 6 months to a year of sun exposure.”

“In a typical extrusion composite design, increased load bearingcapacity capability may be increased while minimizing weight byincorporating internal support structures with internal foam cores.Examples of such designs are taught in U.S. Pat. Nos. 4,795,666;5,728,330; 5,972,475; 6,226,944; and 6,233,892.”

“Increased load bearing capacity, stability and strength of non-extrudedcomposites has been accomplished by locating geometrically shaped corematerial in between structural layers. Examples of pre-formedgeometrically shaped core materials include hexagon sheet material andlightweight woods and foam. Problems associated with typical preformedcore materials include difficulties associated with incorporating thematerials into the extrusion process due to the pre-formed shape of thematerials.”

“Other efforts to increase strength with composite fiber design havefocused on fiber orientation in the composite to obtain increasedstrength to flex ratios. In atypical extrusion composite process, thefiber/fillers are randomly placed throughout the resin/plastic.Therefore increasing strength by fiber orientation is not applicable toan extrusion process.”

“Foam core material has been used in composites for composite materialstiffening, e.g., in the marine industry, since the late 1930's and1940's and in the aerospace industry since the incorporation of fiberreinforced plastics.”

“Recently, structural foam for core materials has greatly improved instrength and environmental stability. Structural core material strengthscan be significantly improved by adding fibers. Polyurethane foams canbe modified with chopped glass fibers to increase flexible yieldstrength from 8,900 psi-62,700 psi.”

“Prior art patents tend to describe foam core materials as rigid orhaving a high-density. However structural mechanical properties of thefoam core tend not to be addressed. A common method to obtain a changein load capacity is to change the density of the material. For example,this can be done in a polyurethane in which water is being used as ablowing agent. The density of a polyurethane decreases with the increasein water concentration.”

“One problem that may occur when a core material and a structuralmaterial are not compatible both chemically and physically isdelamination. Chemical and physical incompatibility can result incomposite structures that suffer structural failures when the corematerial and the structural material separate from one another.”

“[C]oefficient of thermal expansion (CTE)” is discussed in Johnson, aswell as “[t]he conformable core material is injected into and aroundinternal structural support members of an extruded member. Preferably,while the member is being extruded, the core material is injected toreplace air voids within the member. The injection of conformablestructural core material at the same time and same rate as thestructural member is being extruded produces significant improvements byincreasing load bearing capacity, stability and overall strength and byimproving economic feasibility. For example, a rigid polyurethane foamis approximately 10 times less expensive per volume than PVC. Therefore,by replacing some interior volume of an extruded member with foam, thePVC volume is reduced while maintaining the same structural strength orgreater. Therefore, the injection of a conformable foam results in asignificant cost savings. In some applications, the injectableconformable structural core material may be applied to an extrudedmember that has been previously cured.”

“One benefit of an injectable conformable structural core material isthat the core material is not limited by the structural design of thecomposite member because the core material conforms to the geometricshapes present in structure.”

“Although a core material and a structural material may be initiallycombined into a composite member without regard to the CTE's of each,this does not guarantee structural integrity over time. Therefore, theinvention of the application involves tailoring of the conformablestructural core material by the selection of optimal amounts ofstructural fillers to achieve a desired CTE of the materials. The stepof tailoring the structural core material provides a solution forcomposite structural design regardless of the composition of thematerials.”

“One aspect of the invention is directed towards the mechanicalinteraction and the relationship between a selected thermal plastic anda selected foam core material. Thermal plastics have mechanicalproperties that are influenced by environmental temperatures. Forexample, thermal plastics are stronger at colder temperatures but aremore brittle. Thermal plastics are weaker in warmer weather, but aremore flexible.”

“Foam for an internal core material inside a thermal plastic materialmay be tailored to overcome variations in structural strengths ofthermal plastics. For example, an ideal core material is selected topossess thermal expansion properties that offset the thermal sagcharacteristics of thermal plastic structural material that thestructural material experiences due to thermal heating in theenvironment. The thermal expansion of the core and mechanical stiffnessof the composite may be tailored to achieve desired strength andinternal pressure, resulting in mechanical stiffening of the composite.”

“The interaction of thermal sag of the thermal plastic material inrelationship to the thermal expansion of the internal core material maybe considered to select an ideal foam for use with a particular plastic.Ideally, the materials will function as a true composite. Because of theenormous uses of this invention associated with composite design andtheir applications with the overwhelming selection of materials andtheir combinations, the method described herein allows for optimalmaterial pairings to be determined. As internal cross members of astructural member and the exterior structure undergo mechanicalweakening as the temperature increases, a selected internal corematerial having an optimal thermal expansion with enhanced thermalmechanical properties will improve the rigidity and the mechanicalstrength of the combined composite in a manner similar to inflating anautomobile tire to increase mechanical rigidity of the rubber.”

“A further advantage associated with the use of core materials such asfoams are thermal insulation properties of the foam. A significantmechanical advantage is achieved by reducing the heat transfer rate fromthe surface of a structural member to an internal support structure ofthe composite, thereby thermally shielding the internal supportstructure from heat fluctuations and maintaining increased internalstrengths of the cell structures in the composite during elevatedtemperatures.”

“CTE can be tailored in a composite matrix to improve surfacefunctionality between the structural material and the core, therebyreducing the shear stresses that are created by thermal cycling at thecontact interface of the two materials. Polyurethane foam densities aredirectly proportional to the blowing agent, typically water. The lesswater, the tighter the cell structure, which results in higher densityfoams.”

“In a closed cell structure, controlling internal forces caused bythermal cycling produced by the core material can be accomplished bytailoring the CTE. The CTE of a core material may be tailored byadjusting an amount of filler in the core material. For example, fillerssuch as chop fibers and micro spheres will have much lower CTE in thestructural foam. The CTE of glass spheres is approximately 100 timessmaller than most resin materials.”

“Glass spheres or ceramic spheres have enormous compression strength incomparison to the foam cells created by blowing agents. Therefore, theaddition of micro spheres will not only provide the ability to tailorthe CTE of the foam but it will replace low compression strength cellstructures with higher strength cell structures.”

“The incorporation of chop fibers adds dramatic cross structuralstrength throughout the foam. Applicant's mechanical model analysisclearly illustrates an increased strength of materials resulting fromthe presence of core material regardless of the mechanical structure.The analysis was directed to extruded PVC. Some of the extruded PVCmembers were filled with chopped fibers and some were not. The choppedfibers increased strength of the structural member and decreased theCTE. The additives of selected fillers to the foam core materialsillustrate similar characteristics. Selecting appropriate materials fora composite is complicated because composites are not homogeneousmaterials. However, composites are required to function as a homogeneousstructure without structural deviation. The models clearly show howreinforcing fibers increases load bearing capabilities in the compositematerials.”

“Manmade fibers and fillers can be used to improve mechanical propertiesas well as to lower CTE's of a core material. Ideally, filler materialsshould be environmentally stable and malleable into desired geometricconfigurations so that they may be incorporated into a structuraldesign. Examples of fiber materials include fiberglass, carbon andnylon. These fibers can be cut to a specific length with a desireddiameter that can be incorporated into an injection molding processeither from the plastics manufacturer if the desired material is a foamplastic. If the resin is are active material such as polyurethane foam,the fillers and fibers can be combined either in the liquid stage priorto mixing the reactive components or in the foam mixing chamber prior tobeing extruded. The coefficient of thermal expansion is directly relatedto the volume fillers to plastics ratio.”

“Solid core materials can be made from high-density polyurethane,polyureas and epoxy materials etc., having high strength and fast curetimes. These materials may be filled with fillers or micro spheres toproduce high strength injectable core materials.”

SUMMARY OF THE INVENTION

The present invention is generally directed to methods and systems formaking thermoformed structural elements and composites, including theuse of composites, dissimilar or variable processing materials. Acomparison of test data shows the present invention possesses unexpectedimproved properties that the present art does not have.

Materials used originate from polymer waste streams of various origins,primarily engineer grade plastics recovered from electronic-waste andindustrial scrap such as from automotive production. Materials also willinclude fibrous polymer waste recovered from 100% post consumer sourcingor other waste streams where standard methods of recovery have been tolandfill, or waste to energy. The innovative recovery and reuse of thesewaste streams is a key component of our inventiveness and technology.

The present invention avoids the expense and the technical issues of thepresent art on how difficult it is to ‘clean’ said ‘dirty’ recycledmaterials so that they are acceptable to the extrusion process and orthe injection mold process.

The end products can have the same outward appearance as those productsmade by the more demanding, more expensive extrusion process and orinjection process but the present invention's end products can bepre-engineered to have significantly, unexpectedly, improved physicaland chemical properties.

An object of the present invention is a thermoformedstructural-composite construct utilizing the differential betweencertain materials' melt-point(s), said different material(s)thermal-mass, thermal-energy-densities, thermal-energy gradient(s) andstructural integrity I stability in said material(s) in the individualnear-melt-point range vis-a-vis pressure-heat ratio, consistingprimarily of recycled thermoplastics, thermoset plastics, andnon-plastic materials and directly reduced from grind-states to alaminate film and or sheet and or plate-state which is reinforced viafibers, having an average length greater than the composite's thickness,which are tensioned during the manufacture of said composite.

Another object of the present invention is the elimination of costs andloss of time-value associated with separation of waste-stream plasticsinto thermoplastics, thermosets, and non-plastics and then theelimination and loss of time-value of conversion of such materials intofilm and or sheet and or plate before such materials enter athermoforming process.

An object, in reference with the previous paragraphs, of the presentinvent ion is to eliminate the direct labor costs associated with‘grinding’ plastic material, to such a condition, in preparation topelletizing said plastic material, so as to feed said pelletized plasticmaterial before extruding plastic material into sheet, thereby readyingsaid plastic sheet material for shearing and or cutting such, beforeplacement of cut plastic sheet material in a thermoform.

Another object, in reference with the previous paragraphs, of thepresent invention is to eliminate the direct labor costs associated withpelletizing said plastic material, so as to feed said pelletized plasticmaterial before extruding plastic material into sheet, thereby readyingsaid plastic sheet material for shearing and or cutting such, beforeplacement of cut plastic sheet material in a thermoform.

Yet another object, in reference with the previous paragraphs, of thepresent invention is to eliminate the direct labor costs associated withextruding plastic material into sheet, thereby readying said plasticsheet material for shearing and or cutting such, before placement of cutplastic sheet material in a thermoform.

Still another object, in reference with the previous paragraphs, is theelimination of the capital equipment referenced above as the present artpreparation for and conduction of thermoforming. Some examples are themanufacturing equipment directly involved in pelletizing equipment andor the extruding plastic material into sheet equipment. Also eliminatedare handling, storage and indirect equipment, building(s) associatedwith such and the indirect labor costs directly related with maintenanceof said same.

A further object of the present invention is to ease and encourage theuse of post-consumer plastics in thermoform operations. By eliminatingthe need to pelletize and or sheet-extrude plastic material(s) beforethermoforming, the significant costs, involved in ‘separation’ and or‘cleaning’ post-consumer plastic material, are eliminated.

A still further object of the present invention is to utilizewaste-stream plastics which the present art has difficulties ineconomically separating for recycling and using in finished products. Anexample is waste-stream plastics which are a mix of ABS plastic and PVC.ABS and PVC have very similar specific-gravities and melt-points. Whilethe two have the aforementioned commonalities in the present artexamples, difficulties arise when such mixes are extruded or injectionmolded. The present invention allows the use of such plastic mixes inthe manufacture of finished products.

Yet another object of the present invention utilizes the formation, viathe thermoforming operation of structurally bridging internal structuraldifferences. In addition to the above, the present invention providesthe use of ‘foaming’ material(s), included with the above referencedthermoform-able plastic material(s), which when said ‘foaming’ materialsis/are triggered, provides heat, or additional heat, and providespressure or additional pressure to the thermoform process.

A further aspect of the present invention is providing a welldistributed non-thermoform-able material(s) throughout a thermoformeditem. Yet another aspect of the present invention is providing welldistributed thermoform-able materials, of different melt-points,throughout a thermoformed item.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 2 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 3 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 4 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 5 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 6 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 7 illustrates the process of forming an embodiment of athermoformed composite.

FIG. 8 is a flowchart illustrating the production process.

FIG. 9 illustrates an embodiment of various materials combined prior toproduction.

FIG. 10 illustrates an embodiment of various materials combined prior toproduction.

FIG. 11 illustrates an embodiment of various materials combined prior toproduction.

FIG. 12 illustrates an embodiment of various materials combined prior toproduction.

FIG. 13 illustrates an embodiment of various materials combined prior toproduction.

FIG. 14 illustrates a press used to create a sheet of thermoformedcomposite.

FIG. 15 illustrates a thermoformed composite after production.

FIG. 16 illustrates a thermoformed composite after production.

FIG. 17 illustrates a thermoformed composite after production shapedinto a square.

FIG. 18 illustrates a perspective view of a thermoformed composite afterproduction shaped into a square.

FIG. 19 illustrates a thermoformed composite after production shapedinto an octagon.

FIG. 20 illustrates a thermoformed composite after production shapedinto a square sign.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The invention utilizes the manufacturing process known as‘thermoforming’. The thermoform process combines thermally charging amaterial, usually a material such as plastic sheet, to a pliable orplastic-state, and pressing, frequently via a vacuum, into a desiredshape. The thermoformed item is usually then allowed to cool resultingin a hardening of the thermoformed material. Thermoforming is frequentlythe lowest-cost-manufacturing process, over other processes, due in partto usually lower tooling costs and greater factory flexibility.

Thermoform methods and systems are usually subdivided, denoted, as“thin-gauge” and “thick-gauge”. By industry standard, thin-gauge methodsand systems usually mean a finished product that is 1.5 mm (0.059 in.)or less in thickness. Thick-gauge methods and systems usually mean afinished product which is 3 mm (0.12 in.) or greater in thickness.

The present invention is applicable regardless of the final thermoformedproduct's thickness. For clarity, the following will address thetypically encountered ‘thick-gauge’ methods and systems, it beingunderstood that the invention is not limited by the thickness of the endproduct.

The present invention utilizes the difference in melt temperatures ofmaterials commonly encountered in thermoform operations. For example,the melt point for nylon, depending on specific configuration, is above420 degrees F., while amorphous ABS has an effective melt point above220 degrees F. Such differentials in melt point vis-a-vis the thermoformprocess allows for a blending of two or more materials which oncethrough a thermoform can result in specific structural-composites.

The present invention utilizes the differences in energy per unit mass(specific energy or thermal-energy-density) of the materials during theconstruction of the present invention's structural-composites physicalmanifestations. For example, physically mixing two materials withdifferent thermal-energy-densities results in an entity in which heattransfer occurs between the two materials when thermal energy isexternally applied to said mixture.

The present invention utilizes the differences in the thermal-energygradient (rate of temperature change with distance) of the materialsduring the construction of the present invention's structural-compositesphysical manifestations. For example, physically mixing two materialswith different thermal-energy gradients results in an entity in whichthe heat transfer rate occurs between the two materials when thermalenergy is externally applied to said mixture.

An example of a commercial application of two materials, with differentmelt points, which may be configured into a structural-composite iswhere nylon fiber and a plate of ABS plastic is thermoformed at atemperature above the melt point of the ABS plastic but below the meltpoint of the nylon. The standard thermoform combination of heat andpressure will cause the ABS plastic to flow into and surround thenylon-fiber(s).

The character of the physical interface between the nylon weave and theABS plastic is deterministic via the character of the nylon-fiber andgeometry before, during and after the thermoform process. The structuralaspects of the referred to above nylon/ABS structural-composite isdeterministic based on the significantly different mechanical propertiesof the chosen nylon-type, size-length-diameter of individual nylonfiber(s), fiber configuration(s) and chosen ABS plastic-type.

Substitution of the referred above ABS plastic ‘plate’ with ABS plasticpre-extrusion ‘grind’ and reconfiguration of the above referred flexiblenylon-fiber(s) explicitly describes one of the intents of the presentinvention.

Use of a material, in a configuration, such as, but not limited to, ABSplastic pre-extrusion ‘grind’, allows the inclusion of, and mix with,the ‘grind’ material(s) which may or may not be normallythermoform-able. Examples of material(s) which might be ‘included’ andor ‘mixed’, before thermoforming, with a thermoform-able ‘grind’, areceramic(s), metal(s), organic(s) and the like.

Use of a ‘foaming’ material ‘mixed’ with the above referredthermoform-able ‘grind’ allows the deterministic nature of a ‘foaming’material to provide and or enhance the ‘pressure’ aspect of commonlyencountered thermoform operations. Examples of, but not limited to,‘foaming’ materials are polystyrene and or polyurethane. Such ‘foaming’material(s) may be ‘triggered’ to ‘foam’ before, during, or after thethermoforming of the desired structural-composite. In the use of foamingmaterials, such as foaming polyurethane and polystyrene, the activationof the foaming action can be designed to occur before, during, and orafter thermoforming the intended structural composite. Activation of thefoaming action after the construction of the structural composite allowsintended results such as internal pressurizing of said structuralcomposite.

As a general statement, a thermoform-able ‘grind’ has a lower densitythan said ‘grind’ material post-thermoform. That is, the heat/pressureof the thermoform operation densities the ‘grind’. The process of‘squeezing’ or distorting via the thermoform operation, results in anincrease in the surface-area-to-volume (S/V) ratio.

Thermoform-able materials may be categorized as ‘virgin’ (meaningmaterials which do not have a history) ‘post-industrial’ (meaningmaterials which were involved in a manufacturing process but were notconsumed) and ‘post-consumer’ (meaning materials which were completelyused in the manufacture of an item which was sold or consumed by anotherentity).

A specific to the present invention is the recycling of post-consumeritems consisting of relatively high percentages of thermoform-ablematerials. Post-consumer recycle of solid waste has been costly inexecution. Recycling post-consumer plastic solid waste has beenparticularly difficult to achieve. There are a number of reasons forthis inability in the present art, it lacks economic methods tophysically separate plastics of similar specific-gravities but withdifferent physical and or chemical properties. Another reason is thatpost-consumer plastic solid waste is frequently embedded withnon-plastic materials which are frequently uneconomic to be detectable.

The present invention relates to predetermined dimensional structuralcomposites and similar load carrying structural elements. Such loadcarrying structural element design, advancing the present art, addressthe following engineering characteristics: (a) components that do notrust, corrode, or decompose when exposed to fresh water and/or sea waterand/or sewage and/or water-borne creatures, plants, insects or othersuch, (b) components that do not require special handling equipment onthe installation job-site, or factory floor, (c) Components that areeasy to transport to installation job-site, or factory floor, (d)Components that allow for ease of handling and rigging, in installationand or assembly applications, with other structural element sections,(c) Components that do not require new expensive installation equipment,(f) Components that allow for quick field jointing or assembly withother structural element sections, (g) Structural element sections whichare certified and in use by state agencies and approved for use byFederal and State Agencies, (h) Components that allow the use ofexisting engineering design codes, addresses pertinent engineeringdesign consensus standards and specifications, and (i) Composites'elements that are geometrically similar in cross-section to that whichthey are intended to be structural substitutes.

The present invention's economic vitality centers on three aspects.First, full-scale testing of examples of the present invention'sphysical expressions show that said examples providefactors-of-magnitudes higher unit strengths than common grades ofun-reinforced recycled plastic with similar stiffness or load todeflection ratios. As such, modest engineering design efforts willresult in significant reductions in the present invention'smaterials-costs while providing the customer with equivalent productutility,

Second, the present invention's physical manifestations, if engineeredto common un-reinforced recycled plastic engineering characteristics, isof significantly lower mass (or weight) resulting in lowertransportation costs. And, third, the present invention's significantlylower mass (or weight) results in easier assembly or installation laborcosts either in a factory environment and or construction site.

Similar structural aspects are in play involving hardware fastenerapplications such as screws, bolts and nails except that shear isusually an initial structural failure mechanism, where said failure isin the recycled plastic and not the fastener, followed immediately withbending moment carried by the recycled plastic element located betweenthe point of initial shear failure, usually located at or near the shankof the fastener some distance from the surface of the recycled plasticelement. Such structural failure mode behavior provides some mitigationfrom catastrophic structural failure when a givenfastener/lumber-element connection is loaded beyond its capacity.

The present invention's preferred embodiment is a thermoformedstructural-composite construct utilizing the differential betweencertain materials' melt-point(s), said different material(s)thermal-mass, thermal-energy-densities, thermal-energy gradient(s) andstructural integrity/stability in said material(s) in the individualnear-melt-point range vis-a-vis pressure-heat ratio, consistingprimarily of recycled thermoplastics, thermoset plastics, andnon-plastic materials.

The present invention's physical manifestations may be addressed asthermoformed structural-composites constructed utilizing thedifferential between certain materials' melt-point(s), said differentmaterial(s) thermal-mass, thermal-energy-densities, thermal-energygradient(s) and structural integrity/stability in said material(s) inthe individual near-melt-point range vis-a-vis pressure-heat ratio,consisting primarily of recycled thermoplastics, thermoset plastics, andnon-plastic materials and directly reduced from grind-states to alaminate film and or sheet and or plate-state.

An alternative preferred embodiment is as described above with saidthermoformed structural-composites constructed utilizing thedifferential between certain materials' melt-point(s), said differentmaterial(s) thermal-mass, thermal-energy-densities, thermal-energygradient(s) and structural integrity/stability in said material(s) inthe individual near-melt-point range vis-a-vis pressure-heat ratio,consisting primarily of recycled thermoplastics, thermoset plastics, andnon-plastic materials and directly reduced from grind-states to alaminate film and or sheet and or plate-state which is reinforced viafibers, having an average length greater than the composite's thickness,which are tensioned before or during the manufacture of said composite.

An alternative preferred embodiment utilizes the differential betweencertain materials' melt-point(s), said different material(s)thermal-mass, thermal-energy-density, thermal-energy gradient(s) andstructural integrity/stability in said material(s) in the individualnear-melt-point range vis-a-vis pressure-heat ratio. That is, if a firstmaterial A has a melt-point of X, and if a second material B has amelt-point of X+1, and a third material has a melt-point of X+2, for agiven ‘pressure’, then, by thermal-energy-management alone, theresultant thermoformed product is deterministic.

If said materials A's, B's & C's thermal-gradient's nature are known,for a given ‘pressure’, then by thermal-energy-management alone, thelength of time required to thermoform the resultant product isdeterministic. Design of such a deterministic product may begin withmaterial C placed in the thermoform press, followed by material B placedon top of material A, followed in turn with the placement of material Aon top of material B. For a given ‘pressure’, with the addition ofthermal-energy, A will reach its melt-point before B & C. If notconstrained, material A will ‘flow’ past material B and co-mingle withmaterial C. The addition of more thermal-energy will then cause materialB to reach its melt-point and, if not constrained, will co-mingle withthe mixture of A & C.

Specific to this alternative preferred embodiment and demonstratedviable by the inventor, if material C is recycled nylon-fiber thread,and material B is recycled post-consumer electronic-waste Acrylonitrilebutadiene styrene (ABS) plastic and material A is white (translucent)High Impact Polystyrene (HIPS) then the resultant product is asreferenced above. That is, a structural composite consisting of unmeltednylon-fiber thread encased in ABS plastic which in turn is encased inwhite (translucent) HIPS.

A further refinement specific to this alternative preferred embodiment,utilizes pre-heating the nylon-fiber providing a thermal-mass lower thanthe nylon-fiber's melt-point but higher than the ABS melt-point. Thisconfiguration allows the on-set of ABS melt while the ABS insulates theHIPS material. Addition of thermal-energy and pressure causes the ABS toflow and encase the nylon before the HIPS melt-point is reached.

Specific to that configuration referenced above, the resultant producthas nylon-fiber density concentrated on the structural-compositeelement's side opposite to the element's concentration of HIPS on theother side. As such in an application wherein the structural-compositeelement is subject to a bending-moment, such as but not limited to,shelving, with the HIPS surface up and the nylon-fiber concentratedsurface down, the tensile strength of the nylon-fiber will allow for athinner panel than otherwise.

Further, it has been observed that due to the migration of the plasticflowing into and throughout the nylon-fiber, due in part to the pressureaspects of the thermoforming process, said nylon-fiber(s) arestraightened and stretched out. Said tensioning of said nylon-fiber(s)becomes ‘locked’ if the plastic is allowed to fully solidify before saidpressure is released. The said pre-tension-ing of the nylon-fiber andthe resultant pre-compressing of the plastic allows for higher thanotherwise tensile loads on the plastic items of the present invention'sstructural-composite.

Specific to that configuration referenced above in this alternativepreferred embodiment, utilizing the process of pre-heating thenylon-fiber providing a thermal-mass lower than the nylon-fiber'smelt-point but higher than the ABS melt-point, in conjunction with oralternatively as a separate function, the HIPS material may bepre-chilled so as to delay the on-set of the IDPS thermal-gain and itreaching its melt-point.

It being noted that other materials and other materials' geometry applyto the above. For example, the referenced nylon-fiber may be substitutedwith fiberglass and or carbon-fiber and or like materials. Suchsubstitutions, in addition to the originally mentioned nylon, may beused in different geometrical configurations, such as but not limited toscreens, grating, or other micro-structural shapes.

Yet another alternative preferred embodiment utilizes the differentialbetween certain materials' melt-point(s) and the requirement of welldesigned structural-composites for shear transfer between opposingextreme fibers such that, if tensile-tear is optimal, shear strength,for a given composite is greater than compressive strength which in turnis greater than the composite's tensile strength. It being a given thatmost recycled plastic composites structurally fail catastrophically incompression and most strata or laminates catastrophically fail in eithercompression or shear or both.

This alternative preferred embodiment utilizes melt-point differentials.Specific examples for the referenced embodiment may include polyethyleneterephthalate (PET), Nylon-fiber & acrylonitrile butadiene styrene(ABS). Under atmospheric pressure, PET melts at 30 /−480 degrees F.,while Nylon-fiber melts at +/−500 degrees F. and ABS melts at +/−220degrees F. It should be kept in mind that thermoforming pressures,usually, significantly, reduce melt-points and the use of recycledmaterials usually have some ‘contaminates’ which will move individualmelt-points.

To achieve the desired structural-compo site characteristics of afailure-mode based on tensile-tear, rather than catastrophic compressiveor shear failure, a determination is made to the quantity of nylon-fiberat the extreme-fiber and the distance to the neutral axis, in the caseof bending moment. The distance from the extreme-fiber to the neutralaxis determines the thickness of the composite's core material which inthis example consists of the high melt-point recycled PET. To providethe significant shear transfer, between extreme-fibers, required thereferenced PET material is presented to the thermoforming process withpassages which will allow migration, during the thermoforming process,of the nylon-fibers which will sandwich the PET materials. Saidmigration of the nylon-fibers will be encouraged by the melt of ABSmaterial which will sandwich the nylon-fibers and the PET corematerials.

Ingress of the nylon-fibers, through the referenced PET material core'spassages, put said migrated nylon-fibers in shear with the applicationof a bending-moment on this embodiment of the present invention. It canbe seen that to achieve this embodiment the operating temperature andpressure of the thermoform process need only be such as to melt andcause flow of the lower melt-point ABS material.

There are seven different identified types of plastic usually involvedin recycling activities plus a number of other types of plastics andmaterials frequently encountered in co-mingled waste-streams. Some ofthese, but not limited to, materials addressed in the present inventionare: (1) Polyethylene Terephthalate (PEI)—typical melt-point range+/−490 F to 510 F (255 C to 265 C) PET density is greater than water.Recycled PET is frequently used in such items such as textiles, carpets,fiber fillings for apparel, audio cassettes, soft drink bottles, waterbottles, plastic jars, and some plastic wrappings, (2) High-DensityPolyethylene (HDPE)—typical melt-point range+1-250 F to 275 F (120 C to137 C). HDPE is frequently used in plastic milk cartons, juice andliquid detergent containers. Recycled HDPE is used in such items asplastic pipes, agricultural and plant containers, trash cans andbuckets, (3) Vinyl/Polyvinyl Chloride (PVC)—typical melt-pointrange+1-212 F to 500 F (100 C to 260 C). PVC is frequently used inpiping, liquid detergent containers, food wrappings and blisterpackaging. (4) Low-Density Polyethylene (LDPE)—typical melt-pointrange+/−257 F to 278 F (125 C to 137 C). LDPE is frequently used inplastic bags and garment bags. Recycled LDPE is frequently used inplastic trash bags, plastic tubing and plastic lumber. (5) Polypropylene(PP)—typical melt-point range+/−320 F to 330 F (160 C to 165 C). PP isfrequently used in the automotive industry, also for bottle tops,battery casings and carpets. (6) Polystyrene (PS)—typicalmelt-range+/−365 F to 500 F (180 C to 260 C). PS is frequently used inmeat packing, protective packing and packing foam. (7) OTHER: Usuallylayered or mixed plastic. Common examples are headlight lenses andsafety glasses; No recycling potential—must be landfilled. (8) polyvinylalcohol (PVA)—typical melt-point range+/−356 F to 374 F (180 C to 190C). (9) Acrylonitrile butadiene styrene (ABS)—typical melt-pointrange+/−218 F to 260 F (103 C to 128 C). (10) High impact polystyrene(H1PS)—typical melt-point range+/−392 F to 500 F (200 C to 260 C). (11)polylactide (PLA) typical melt-point range+/−302 F to 320 F (150 C to160 C). (12) Nylon—typical melt-point range+1-428 F to 510 F (220 C to265 C). (13) Polycarbonate (PC)—typical melt-point range+/−510 F (+/−265C). (14) Acrylic-typical melt-point range+/−572 F to 600 F (+/−300 to315 C). (15) Fiberglass—typical melt-point range+/−2075 F (+/−1121 C).

Another, special case, is shape memory plastics (SMP). SMPs are plasticswhich if deformed using heat and external force, and then are allowed tocool-harden, when they are heated again they return to their originalshape. This is a typical characteristic in plastics having across-linked structure. SMPs do not usually melt so recycling them isdifficult.

Those knowledgeable in the present art of recycling plastics with orwithout ‘contaminates’ will understand that equipment, facilities andoperations usually required to complete the recycling process includesmany and varied configurations. To name but a few: air classifiers,mechanical classifiers, sink-float tanks, hydrocyclones, frothflotation, dissolution, hydrolisys, pyrolysis, laser spectral analysis,and electrostatic separation.

The present invention avoids most of the expenses associated with theabove referenced. What is required is atypically encountered operationknown as mechanical grinding. Recycled plastics are fed into mechanicalgrinders where they're ground into flakes. Most post-consumer plastics,in addition to being of, as referenced above, a mixed plastic nature,collected for recycling have traditionally nonrecyclable materialsattached such as paper, metal parts or glass. The product of such anoperation is known in the industry as “dirty” regrind. Traditionally,this material would have to be “cleaned” in order to be recycled.

The above referenced ‘cleaning’ operation usually first uses air toremove materials lighter than plastic, such as paper labels. The grit isthen passed through scrubbers to materials such as oils, glue residuesand inorganic dust. The plastic grit is then run through a “float/sink”tank(s) where heavier plastics heavier than water sink and lighterplastics float.

The recovered plastic is usually re-melted and converted into pelletform before being used in traditional injection-molding, blow-molding orextrusion-molding.

FIG. 1 illustrates the process of forming an embodiment of athermoformed composite. Upper plate 1 and lower plate 2 hold a matcheddie set having a male segment 3 and a female segment 4. Addressing FIG.1, from left to right, the left-most plates 1 and 2 hold the matched dieset 3 and 4. A thermoform-able material 5, which in the present art isfrequently pre-heated, is placed between die set 3 and 4. Through heatand pressure, thermoform-able material 5 is converted into the desiredend-shape.

The desired shape may be flat, V-shaped, rounded, or any other bent ormolded shape. Different die sets are used to achieve the differentdesired shapes. The thermoform-able material 5 is removed from the dieset once it has completely cooled. It should be noted that the term“thermoform-able” is used here as reference to specific material(s)melt-point for a given thermal-mass plus pressure.

FIG. 2 illustrates the process of forming an embodiment of athermoformed composite. The process of FIG. 2 is similar to the processof FIG. 1. Plates 1 and 2 hold the matched die set 3 and 4. Unlike FIG.1, that demonstrates a single thermoform-able material 5, FIG. 2 showsthree distinct materials 5, 6 and 7. Through the thermoforming processof heat and pressure, materials 5, 6 and 7 are structurally laminatedinto a finished desired product.

This thermoforming process is sometimes known as the ‘strata-process’.As the term ‘strata-process’ implies the ‘laminated’ together materialsretain their individual structural integrities. That is, for example asshown in FIG. 2, the thermoforming process of materials 5, 6 and 7provides the intended results of two distinct shear-planes. Said twodistinct shear-planes being that structural interface between materials5 and 6 and materials 6 and 7.

FIG. 3 illustrates the process of forming an embodiment of athermoformed composite. The process of FIG. 3 is similar to the processof FIG. 1. Addressing FIG. 3, from left to right, the left-most plates 1and 2 hold the matched die set 3 and 4. Similar to FIG. 2, FIG. 3 showsthree distinct materials 5, 6, and 7 which through the thermoformingprocess of heat and pressure are structurally melded into a singlefinished desired structural composite 8. Composite 8 is a productwithout defined distinct shear-planes.

An example of this process is the pre-thermoforming sandwiching of afiber material such as nylon fiber and or fiberglass strand and orcarbon-fiber material 6 having a melt-point higher than the material(s)5 and 7. The invention's thermoforming operation elevates thethermal-mass of material(s) 5 and 7 to or above the melt-point ofmaterial(s) 5 and 7 but does not approach the melt-point of the fibermaterial 6. Through the invention's thermoforming process, materials 5,6 and 7 merge together to form a single structural entity 8 withoutdistinct shear-planes.

FIG. 4 illustrates the process of forming an embodiment of athermoformed composite. The process of FIG. 4 is similar to the processof FIG. 1. FIG. 4 is similar to FIG. 3 but with the addition of material9. Plates 1 and 2 hold the matched die set 3 and 4. As in FIG. 3, FIG. 4shows three distinct materials 5, 6 and 7 which through thethermoforming process of heat and pressure are structurally melded intoa single finished desired structural composite 8. Composite 8 is aproduct without defined distinct shear-planes.

FIG. 4 also shows referenced material 9. The present invention allowsthe use of material which has not been pre-formed into sheets and orplates. The present invention allows the formation of a combination of asingle structural composite 8 with a strata material 9 having a distinctshear-plane.

FIG. 5 illustrates the process of forming an embodiment of athermoformed composite. The process of FIG. 5 is similar to the processof FIG. 1. FIG. 5 is similar to FIG. 4 except that material 9 is of adifferent nature. Materials 5, 6, and 7 and material 9 are thermoformedsuch that the present invention's thermoforming operations melds withmaterials 5 6 and 7 and material 9 to form a single structural entity 10without distinct shear-planes.

FIG. 6 illustrates the process of forming an embodiment of athermoformed composite. The process of FIG. 6 is similar to the processof FIG. 1. FIG. 6 is similar to FIG. 5 but without any pre-formed sheetmaterials 5, 6 and 7 as depicted in other previous FIGURES. Material 9is thermoform-able material(s) or thermoform-able materials(s) andnon-thermoform-able material(s) mixture. The present invention's directreduction of material 9 to a single structural entity without distinctshear-planes, reduces direct materials costs.

Examples include thermoform-able recycled post-consumer electronic-wasteABS plastic grind and or recycled nylon fiber, recycled polypropeneand/or the like. Mixtures of thermoform-able and non-thermoform-ablegrind may include non-thermoform-able materials such as titaniumdioxide, ceramic dust, metal filings, marble dust, shale flake and/orthe like. It should be noted that the terms “thermoform-able” and“non-thermoform-able “are used here as reference to a specificmaterial's melt-point for a given thermal-mass plus pressure. As such,for example, a mixture of ABS grind with nylon fibers and a thermoformoperating effective temperature higher than the melt-point for a chosenABS but lower than the melt-point for a chosen nylon would by definitionhave the nylon to be considered “non-thermoform-able” material(s) forthe example's mixture.

FIG. 7 illustrates the process of forming an embodiment of athermoformed composite. The process of FIG. 7 is similar to the processof FIG. 1. FIG. 7 is similar to FIG. 6 but withstructural/micro-structural elements 11 included with theafore-referenced recycled grind material(s) 9. Said structural elements11 may include recycled fiberglass air filter structures, recycled spentindustrial filter structures, recycled plastic extrusion, metallic andmetallic/plastic screens, and or scraps of such and similar screeningand such for the purpose of forming a single structural entity withoutdistinct shear-planes.

Now referring to FIG. 8, a flowchart illustrates the production process.Various sources are gathered into a pre-processing facility 811 or awarehouse or sorting facility 812. Pre-processing facility 811 may beused for size reduction or cleaning if needed. Some of the variousmaterial sources may be: (801) EScrap or Auto scrap recycler Polymerrelated and or textile; (802) Textile recycler that includes PET, Nylonsfrom carpet, clothing or seating; (803) C&D or Glass Recycler-fiber,granules or matting; (804) Waste firms, recyclers and WTE plants, anysource of waste, packaging, materials handling, or industrialby-products.

The material is retrieved from the pre-processing facility 811 orwarehouse facility 812 and brought to a production facility 820. Theproduction facility 820 uses presses to create sheets or blanks. Furtherprocessing such as thermoforming, cutting, painting, silk screening orlaser etching may also be performed.

After production, the new sheets or blanks are sent out of theproduction facility 820 to be used for various products. Some of theseproducts consist: (830) Sign market or Wayfinders, which includes ADAcompliant signage, Thermoformer, or other value add processors; (831)barrier applications such as paneling or sea wall/casement; (832)highway signage and other outdoor vehicle and pedestrian signage (e.g.stop signs, parking signs, etc.).

Many sources may be used for the material. Primary sourcing arecertified EScrap recovery facilities such as MBA Polymers, GEEP, MEXTEK,CEAR, SIMS and others. By sourcing polymers generated from these EScraprecovery locations, a new end usage is being created for thisproblematic scrap. In addition, other non polymer material, especiallyglass from CRT monitors, are hoped to be included as part of thecomposite recipe, once deemed safe. If safety cannot be assured, theother glass sourcing mentioned, will suffice.

These recovery processes are mandated and policy driven under producerresponsibility policies or as part of landfill diversion requirementsaround the world. The shortage of many materials in the EScrap streamdrive the overall recovery efforts. In so doing, the larger volumematerials are ignored. This is comparable to the illegal poaching ofrare species such as Rhinos in order to get the horn, but leave thecarcass of the rest of the animal to waste. We help provide and supportthe legitimate recovery of materials domestically and around the globe.

Similar materials are also able to be recovered from auto scrap,packaging and consumer goods. Other material sourcing as part of thecomposite recipe include glass fibers recovered from building insulationor made from recovered glass from packaging, old insulation, CRT glass,or other post consumer glass fiber sourcing.

Such programs are often part of a closed loop process by the OEM'S ofthe glass products or from waste firms as part of their waste contracts.Examples would be Owens Corning, Waste Management, Johns Manville, andCertainTeed who need recovery of these materials to meet internalcorporate pledges (CSR) or as part of a requirement in order to sell newmaterials. The composite disclosed herein is a value added alternativeto landfill and improper disposal.

The other component materials are recovered from post consumer textilewaste; specifically flooring waste and or carpet. The key materialsrecovered from this sourcing channel are nylon (polyamide) waste, PP(polypropylene) waste or PET waste. The fibrous components of thesematerials lend themselves to helping create a matrix type structureduring the melting and forming of the composites.

In addition, these materials can also be pre melted to form a basematerial or pelletlflake/chip, that can be used in the compositestructure as well. Other flooring components such as PVC will play arole in composites where the end market will allow PVC content orprefers it. PVC has an inherently flame retardant quality that lendsitself to certain applications other materials do not provide. Since, itis also available as a post consumer material in large supply, we see itas an interchangeable option as needed.

In referring to the EScrap supply earlier, we also have incorporated PVCwire strippings from EScrap recovery facilities or auto scrap/metalscrap plants. This is another highly problematic scrap where ourcomposite helps to provide an effective alternative solution tolandfill, burning or illegal disposal.

These post consumer waste materials are all then shipped to a centrallocation in various forms: bales of fiber, chips or pellets primarily.They can also be entire parts that we can process ourselves if need be.After these materials arrive at the centralized location, variousblending methods. This can range from hand blending in a bucket to largebatch blending in industrial blending equipment to meet volume needs.

The blending of these large distinctive and problematic waste streamshave not been done before and offer a unique set of properties andperformance that add value and offer a value added non landfill or nonincineration option heretofore not previously performed. Furtherrefining and blending is accomplished at the hydraulic press ormechanical press. It is at that point, that layering of the materialsand or the dispersion of materials in a mold of various shapes can beperformed. These layers allow for the melt differentials or similaritiesto complement each other in a unique and performance enhancing fashion.

A similar example might be the way concrete is laid down using rebar andor fiber additives. Certain systems for charting carbon fiber compositesuse a sheet process built layer upon layer under heat. The compositedisclosed herein uses unique combinations of waste materials that eachcontribute to adding strength, flame retardancy, impact or temperaturetolerance improvement and improved weather-ability in order to create afinished sheet products to be used in various end applications as is, orto be submitted for further processing such as thermoforming, cutting,painting, silk screening or laser etching.

FIG. 9 illustrates various materials combined prior to production.Layered above a material sheet 900, are a fiberglass layer 901 and foamor wood layer 902. Other materials may also be used in place of thelayers. Sheets of different materials may also be used as long as theyprovide a solid outer layer that helps the layered materials retain asturdy shape while pressed during production.

FIG. 10 illustrates various materials combined prior to production.Layered above a material sheet 1000, are a fiberglass layer 1001 andfoam or wood layer 1002. The layered materials 1001 and 1002 may bearranged in a pre-determined shape. The shape depicted in FIG. 10 is anoctagon shape (e.g. stop sign). Other materials may also be used inplace of the layers. Sheets of different materials may also be used aslong as they provide a solid outer layer that helps the layeredmaterials retain a sturdy shape while pressed during production.

FIG. 11 illustrates various materials combined prior to production.Layered above a material sheet 1100, are various forms of string, yarnand thread 1101. Other materials may also be used in place of thelayers. Sheets of different materials may also be used as long as theyprovide a solid outer layer that helps the layered materials retain asturdy shape while pressed during production.

FIG. 12 illustrates various materials combined prior to production.Layered above a material sheet 1200, are various forms of string, yarnand thread 1201. Other materials may also be used in place of thelayers. Sheets of different materials may also be used as long as theyprovide a solid outer layer that helps the layered materials retain asturdy shape while pressed during production.

FIG. 13 illustrates various materials combined prior to production.Layered above a material sheet 1300, are various forms of string, yarnand thread 1301. Another material sheet 1305 is placed on top thestring/yarn/thread layer 1301. Material sheets 1300 and 1305 cooperateto sandwich the string/yam/thread layer 1301. Other materials may alsobe used in place of the layers. Sheets of different materials may alsobe used as long as they provide a solid outer layer that helps thelayered materials retain a sturdy shape while pressed during production.

FIG. 14 illustrates an exemplary press used to produce the finishedcomposite sheet. The press is known in the art and provides equallydispersed pressure along the top and bottom of the sheet. This equallydispersed pressure ensures the sheet has equal thickness throughout itsplanar axis. Preferably, the press uses a hydraulic pressure to compressthe layers. If thermoforming, an intense heat is also used to thermally“melt” the layers together and create a single bonded layer

FIG. 15 illustrates a thermoformed composite after production. Thecomposite comprises material sheet layers and a string/yam/thread layer.The layers have been compressed together and heated to create a singlecomposite sheet. The new composite sheet comprises the strengths of theindividual layers from the pre-production. The new composite sheet maybe further shaped and formed into a pre-determined shape to be used forsignage, paneling, etc. The new composite sheet is designed to belighter, stronger, and more eco-friendly than the conventional signagematerial. The inherent, yet unique qualities, such as impact properties,flame retardancy, rigidity, cold crack resistance and melt varianceseach contribute to end properties that allow for uses that are notachievable if each material were to be used on its own.

FIG. 16 illustrates a thermoformed composite after production. Thecomposite comprises material sheet layers and a string/yam/thread layer.The layers have been compressed together and heated to create a singlecomposite sheet. The new composite sheet comprises the strengths of theindividual layers from the pre-production. The new composite sheet maybe further shaped and formed into a pre-determined shape to be used forsignage, paneling, etc. The new composite sheet is designed to belighter, stronger, and more eco-friendly than the conventional signagematerial. The inherent, yet unique qualities, such as impact properties,flame retardancy, rigidity, cold crack resistance and melt varianceseach contribute to end properties that allow for uses that are notachievable if each material were to be used on its own.

FIG. 17 illustrates a thermoformed composite after production. Thecomposite comprises material sheet layers and another material layer.The layers have been compressed together and heated to create a singlecomposite sheet. The new composite sheet comprises the strengths of theindividual layers from the pre-production. The new composite sheet maybe further shaped and formed into a pre-determined shape to be used forsignage, paneling, etc.

In FIG. 17, the composite sheet has been cut and shaped into a square.Other shapes are also allowable. The new composite sheet is designed tobe lighter, stronger, and more eco-friendly than the conventionalsignage material. The inherent, yet unique qualities, such as impactproperties, flame retardancy, rigidity, cold crack resistance and meltvariances each contribute to end properties that allow for uses that arenot achievable if each material were to be used on its own.

FIG. 18 illustrates a perspective view of a thermoformed composite afterproduction. The composite comprises material sheet layers and anothermaterial layer. The layers have been compressed together and heated tocreate a single composite sheet. The new composite sheet comprises thestrengths of the individual layers from the pre-production. The newcomposite sheet may be further shaped and formed into a pre-determinedshape to be used for signage, paneling, etc.

In FIG. 18, the composite sheet has been cut and shaped into a square.Other shapes are also allowable. The new composite sheet is designed tobe lighter, stronger, and more eco-friendly than the conventionalsignage material. The inherent, yet unique qualities, such as impactproperties, flame retardancy, rigidity, cold crack resistance and meltvariances each contribute to end properties that allow for uses that arenot achievable if each material were to be used on its own.

FIG. 19 illustrates a thermoformed composite after production. Thecomposite sheet has been shaped into an octagon form. The new compositesheet is designed to be lighter, stronger, and more eco-friendly thanthe conventional signage material. The inherent, yet unique qualities,such as impact properties, flame retardancy, rigidity, cold crackresistance and melt variances each contribute to end properties thatallow for uses that are not achievable if each material were to be usedon its own.

FIG. 20 illustrates a thermoformed composite after production. Thecomposite sheet has been shaped into a square sign. The sign includesgraphics and lettering that is formed during the thermoforming process.This is done by having the graphic and/or lettering as part of anegative imprint of the press dies. This allows the layered materials tonot be fully compressed in the negative imprint areas while completelycompressed in the non-negative imprint areas.

Negative imprints in the dies are common to the art of molding andcasting. The new composite sheet is designed to be lighter, stronger,and more eco-friendly than the conventional signage material. Theinherent, yet unique qualities, such as impact properties, flameretardancy, rigidity, cold crack resistance and melt variances eachcontribute to end properties that allow for uses that are not achievableif each material were to be used on its own.

The invention uses a unique combination of materials recovered fromvarious waste streams or recycling processes to create various recipesand formulas to serve a variety of end markets. The combinations fromthese unrelated sources and material types are combined and formed,using thermoforming and hydraulic pressure to create composites notcurrently available. They also divert materials from landfills orillegal disposal in to a value added series of products such as signage,sheet and board type products for the disability community, military orgovernment sector and transportation markets.

The inherent, yet unique qualities, such as impact properties, flameretardancy, rigidity, cold crack resistance and melt variances eachcontribute to end properties that allow for uses that are not achievableif each material were to be used on its own. Energy, emissions and watersavings from the use of such materials have also been documented invarious life cycle studies by the EPA and NGO's. Thereby making thesematerials and/or end products suitable for numerous environmentalcredits; LEED, Carbon offsets and diversionary credits.

As in the claims above to include the use of a ‘foaming’ material‘mixed’ with the above referred thermoform-able ‘grind’ allows thedeterministic nature of a ‘foaming’ material to provide and or enhancethe ‘pressure’ aspect of commonly encountered thermoform operations.Such ‘foaming’ material(s) may be ‘triggered’ to ‘foam’ before, during,or after the thermoforming of the desired structural-composite. In theuse of foaming materials, the activation of the foaming action can bedesigned to occur before, during, and or after thermoforming theintended structural composite. Activation of the foaming action afterthe construction of the structural composite allows intended resultssuch as internal pressurizing of said structural composite.

It will be apparent to those skilled in the art, that is, to those whohave knowledge or experience in this area of technology that many usesand design variations are possible for the invention disclosed herein.The above detailed discussion of various alternative and preferredfeatures and embodiments will illustrate the general principles of theinvention. Other embodiments suitable for other applications will beapparent to those skilled in the art given the benefit of thisdisclosure. The particular combination of parts described andillustrated herein is intended to represent only certain embodiments ofthe present invention.

1. A thermoformed structural-composite construct made by a process comprising the steps of: providing a first material having a first melting pointing, a first thermal mass, a first thermal energy density, a first thermal-energy gradient, and a first structural integrity, providing a second material having a second melting pointing, a second thermal mass, a second thermal energy density, a second thermal-energy gradient, and a second structural integrity, combining under compression between a first matched die and a second matched die to create pressure and heat applied to said first and second materials, said combination uses the differential between said first and second melting points, thermal-mass, thermal-energy-densities, thermal-energy gradients and structural integrities in the individual near-melt-point range vis-a-vis pressure-heat ratio for first said material but does not approach the melting point for the second material; producing a third composite material thermoformed from the merged compression of said first material with said second material, said third composite material thermoformed without distinct shear planes, and configuring the third composite material for a predetermined use.
 2. The construct prepared according to claim 1 wherein said materials include one of the following: phase-separated mixtures, immiscible blends, Polyethylene Terephthalate (PET), or poly(vinyl alcohol) (PVA).
 3. The construct prepared according to claim 1 wherein said materials include polymer originating from waste streams of various origins, cellulose acetate materials from cigarette filters, or packaging fillings.
 4. The construct prepared according to claim 1 wherein said materials include co-mingled material.
 5. The construct prepared according to claim 1 wherein said materials include one of the following: High-Density Polyethylene (HDPE), Vinyl/Polyvinyl Chloride (PVC), Low-Density Polyethylene (LDPE), Polypropylene (PP), Polystyrene (PS), Acrylonitrile butadiene styrene (ABS), High impact polystyrene (HIPS), polylactide (PLA), Nylon, Polycarbonate (PC), Acrylic, or Fiberglass.
 6. The construct prepared according to claim 1 wherein said materials include one of the following: thermoset epoxies, thermoset polyesters, thermoset silicones, thermoset phenolics, vulcanized rubber, polyoxybenzylmethylenglycolanhydride (bakelite), cross-linked polyethylene (PEX), Polyurethane (PU), carbon fiber, flame retardant plastics, fiber reinforced plastics.
 7. The construct prepared according to claim 1 wherein said materials are one of the following: glass filled plastics, cured silicone, mixed plastics, metals, paper, or shape memory plastics (SMP).
 8. The construct prepared according to claim 1 wherein said materials possess one or more of the following: pigments, inks, adhesives, chlorine, styrene, and Olefin.
 9. The construct prepared according to claim 1 wherein said materials include engineered grade plastics recovered from electronic waste, electrical waste, and automotive waste.
 10. The construct prepared according to claim 13 wherein said materials are one of the following: recycled thermoplastics, thermoset plastics, and non-plastic materials.
 11. The method of claim 1 wherein said materials directly reduced from a grind-state to one or more of the following states: film-state, sheet-state, plate-state, laminate film-state, laminate sheet-state, laminate plate-state.
 12. The construct prepared according to claim 1 wherein said materials are reinforced via fibers, tensioned during the manufacture of said composite, or tensioned during the manufacture of said composite. 